Brush gauge and related methods

ABSTRACT

A brush gauge includes a stepped barb and an arcuate ledge. The stepped barb and the arcuate ledge partially define an aperture.

FIELD OF THE DISCLOSURE

This disclosure relates generally to brush manufacturing quality control and, more particularly, to a brush gauge and related methods.

BACKGROUND

In recent years, cosmetic brushes have been developed to have brush heads with specific dimensions. For example, cosmetic brushes are constructed to have brush heads with precise heights, widths, and tapers. These brush heads are typically made of natural or synthetic bundles of flexible bristles. It is further common practice to measure these brush heads during a quality control step of the manufacturing process to ensure they meet the specified dimension requirements, or, are within a certain tolerance of the specified dimension requirements.

Known measurement techniques for brush head quality control utilize hand-held calipers to measure the brush heads. However, the calipers cause the flexible bristles to bend. Additionally, measurement points of the brush heads vary and/or are subjective. Thus, the resultant measurements are imprecise. Therefore, a need exists for a measurement tool for determining whether brush heads are correctly sized.

SUMMARY

In one aspect, a brush gauge includes a stepped barb and an arcuate ledge. The stepped barb and the arcuate ledge partially define an aperture.

In another aspect, a brush gauge includes an arcuate ledge, a first stepped barb, and a second stepped barb. The first stepped barb is connected to the arcuate ledge. The second stepped barb is connected to the arcuate ledge.

In another aspect, a brush gauge includes a body. The body defines an aperture. The body comprises a stepped barb and an arcuate ledge. The stepped barb extends into the aperture. The arcuate ledge extends into the aperture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example brush gauge;

FIG. 2 is an enlarged partial perspective view of the brush gauge of FIG. 1 taken from section A of FIG. 1;

FIG. 3 is an enlarged partial perspective view of the brush gauge of FIGS. 1 and 2 taken from section A of FIG. 1 with a brush placed in a first opening of the brush gauge;

FIG. 4 is a cross-sectional view of the brush gauge of FIGS. 1-3 taken along line 4-4 of FIG. 1;

FIG. 5 is a cross-sectional view of the brush gauge of FIGS. 1-4 taken along line 5-5 of FIG. 1;

FIG. 6 is a cross-sectional view of the brush gauge of FIGS. 1-5 taken along line 6-6 of FIG. 1;

FIG. 7 is a schematic view of an example brush testing system including the brush gauge of FIGS. 1-6; and

FIG. 8 is a flowchart of an example method to test brushes, which may be implemented by the example brush testing system of FIG. 7.

DETAILED DESCRIPTION

As explained herein, the present disclosure provides a brush gauge that may be used to measure brush heads. Additionally, the brush gauge may be included in a brush testing system. As non-limiting examples, the brush gauge may define an opening and may have an internal ledge and opposing barbs to verify brush head dimensions.

With reference to FIGS. 1-3 and 6, a brush gauge 100 includes a body 102. The body 102 includes a first arcuate ledge 104, a first stepped barb 106, a second stepped barb 108, a second arcuate ledge 112, a third stepped barb 114, and a fourth stepped barb 116.

With reference to FIGS. 1-6 the body 102 also includes a top portion 120 and a bottom portion 122. Referring to FIGS. 1, 2, and 6, the top portion 120 defines a first top opening 126 and a second top opening 128. Referring to FIGS. 1 and 2, the first top opening 126 has a first top perimeter 130. The second top opening 128 has a second top perimeter 132. Referring to FIGS. 1, 2, 4, and 6, the bottom portion 122 defines a first bottom opening 136 and a second bottom opening 138. Referring to FIGS. 1 and 2, the first bottom opening 136 has a first bottom perimeter 140. The second bottom opening 138 has a second bottom perimeter 142.

With reference to FIGS. 1, 2, 4, and 6, the top portion 120 includes a first top arcuate wall 146, a first top sloped wall 148, a first stepped wall 150, and a first side wall 152. Referring to FIGS. 1 and 2, the top portion also includes a first end wall 154, a second side wall 156, a second stepped wall 158, and a second top sloped wall 160. Referring to FIG. 6, the first top arcuate wall 146, the first top sloped wall 148, the first stepped wall 150, the first side wall 152, the second side wall 156, the second stepped wall 158, and the second top sloped wall 160 define the first top opening 126. Referring to FIG. 4, the first end wall 154 also defines the first top opening 126.

With reference to FIGS. 1, 2, 4, and 6 the bottom portion 122 includes a first bottom arcuate wall 164 and a first bottom sloped wall 166. Looking specifically at FIG. 6, the bottom portion 122 also includes a second bottom sloped wall 168. The bottom portion 122 also includes the first stepped wall 150, the first side wall 152, the second side wall 156, and the second stepped wall 158. Referring to FIGS. 1 and 4, the bottom portion 122 also includes the first end wall 154. Referring to FIG. 6, the first bottom arcuate wall 164, the first bottom sloped wall 166, the first stepped wall 150, the first side wall 152, the second side wall 156, the second stepped wall 158, and the second bottom sloped wall 168 define the first bottom opening 136. Referring to FIG. 4, the first end wall 154 also defines the first bottom opening 136.

With reference to FIGS. 1, 2, 5, and 6, the top portion 120 also includes a second top arcuate wall 172, a third top sloped wall 174, a third stepped wall 176, and a third side wall 178. Referring to FIG. 1 the top portion 120 also includes a second end wall 180, a fourth side wall 182, a fourth stepped wall 184, and a fourth top sloped wall 186. Referring to FIG. 6, the second top arcuate wall 172, the third top sloped wall 174, the third stepped wall 176, the third side wall 178, the fourth side wall 182, the fourth stepped wall 184, and the fourth top sloped wall 186 define the second top opening 128. Referring to FIG. 5, the second end wall 180 also defines the second top opening 128.

With reference to FIGS. 5 and 6 the bottom portion 122 also includes a second bottom arcuate wall 190 and a third bottom sloped wall 192. Referring specifically to FIG. 6, the bottom portion 122 also includes a fourth bottom sloped wall 194. The bottom portion 122 also includes the third stepped wall 176, the third side wall 178, the fourth side wall 182, and the fourth stepped wall 184. Referring to FIGS. 1 and 5, the bottom portion 122 also includes the second end wall 180. Referring to FIG. 6, the second bottom arcuate wall 190, the third bottom sloped wall 192, the third stepped wall 176, the third side wall 178, the fourth side wall 182, the fourth stepped wall 184, and the fourth bottom sloped wall 194 define the second bottom opening 138. Referring to FIG. 5, the second end wall 180 also defines the second bottom opening 138.

With reference to FIG. 6, the first top arcuate wall 146 is connected to the first top sloped wall 148. The first top sloped wall 148 is connected to the first stepped wall 150. The first stepped wall 150 is connected to the first side wall 152. Referring to FIG. 1, the first side wall 152 is connected to the first end wall 154. The first end wall 154 is connected to the second side wall 156. Referring back to FIG. 6, the second side wall 156 is connected to the second stepped wall 158. The second stepped wall 158 is connected to the second top sloped wall 160. The second top sloped wall 160 is connected to the first top arcuate wall 146.

Still with reference to FIG. 6, the first bottom arcuate wall 164 is connected to the first bottom sloped wall 166. The first bottom sloped wall 166 is connected to the first stepped wall 150. The second stepped wall 158 is connected to the second bottom sloped wall 168. The second bottom sloped wall 168 is connected to the first bottom arcuate wall 164.

With reference again to FIG. 6, the second top arcuate wall 172 is connected to the third top sloped wall 174. The third top sloped wall 174 is connected to the third stepped wall 176. The third stepped wall 176 is connected to the third side wall 178. Referring to FIG. 1, the third side wall 178 is connected to the second end wall 180. The second end wall 180 is connected to the fourth side wall 182. Referring to FIG. 6, the fourth side wall 182 is connected to the fourth stepped wall 184. The fourth stepped wall 184 is connected to the fourth top sloped wall 186. The fourth top sloped wall 186 is connected to the second top arcuate wall 172.

With reference to FIG. 6, the second bottom arcuate wall 190 is connected to the third bottom sloped wall 192. The third bottom sloped wall 192 is connected to the third stepped wall 176. The fourth stepped wall 184 is connected to the fourth bottom sloped wall 194. The fourth bottom sloped wall 194 is connected to the second bottom arcuate wall 190.

With reference to FIGS. 1, 2, and 4, the first top perimeter 130 is larger than the first bottom perimeter 140. Thus, the first arcuate ledge 104 is a shoulder defined between the top portion 120 and the bottom portion 122. Additionally, with reference to FIG. 6, the first stepped wall 150 and the second stepped wall 158 are stepped because the first top perimeter 130 is larger than the first bottom perimeter 140. Further, the first top opening 126 is larger than the first bottom opening 136.

With reference to FIGS. 1, 2, and 5, the second top perimeter 132 is larger than the second bottom perimeter 142. Thus, the second arcuate ledge 112 is a shoulder defined between the top portion 120 and the bottom portion 122. Additionally, with reference to FIG. 6, the third stepped wall 176 and the fourth stepped wall 184 are stepped because the second top perimeter 132 is larger than the second bottom perimeter 142. Further, the second top opening 128 is larger than the second bottom opening 138.

With reference to FIGS. 1, 2, and 6, the first stepped barb 106 and the second stepped barb 108 extend into the first top opening 126 and the first bottom opening 136. The first stepped barb 106 and the second stepped barb 108 are opposite one another. The third stepped barb 114 and the fourth stepped barb 116, extend into the second top opening 128 and the second bottom opening 138. The third stepped barb 114 and the fourth stepped barb 116 are opposite one another.

Referring again to FIGS. 1, 2, and 6, the first top opening 126 is in communication with the first bottom opening 136 to form a first aperture 196. In other words, the body 102 defines the first aperture 196. More specifically, referring to FIG. 6, the first aperture is thus defined by the first arcuate ledge 104, the first top arcuate wall 146, the first top sloped wall 148, the first stepped wall 150, the first side wall 152, the second side wall 156, the second stepped wall 158, the second top sloped wall 160, the first bottom arcuate wall 164, the first bottom sloped wall 166, and the second bottom sloped wall 168. Additionally, referring to FIG. 1, the first aperture 196 is also defined by the first end wall 154. The first arcuate ledge 104 is opposite the first end wall 154.

Referring still to FIGS. 1, 2, and 6, the second top opening 128 is in communication with the second bottom opening 138 to form a second aperture 198. In other words, the body 102 defines the second aperture 198. More specifically, referring to FIG. 6, the second aperture 198 is thus defined by the second arcuate ledge 112, the second top arcuate wall 172, the third top sloped wall 174, the third stepped wall 176, the third side wall 178, the fourth side wall 182, the fourth stepped wall 184, the fourth top sloped wall 186, the second bottom arcuate wall 190, the third bottom sloped wall 192, and the fourth bottom sloped wall 194. Additionally, referring to FIG. 1, the second aperture 198 is also defined by the second end wall 180. The second arcuate ledge 112 is opposite the second end wall 180.

With reference to FIG. 3, an example of a brush 200 includes a brush head 202 and a handle 204. In some examples, the brush 200 also includes a ferrule 206. The brush head 202 is made up of a plurality of bristles 208. In some examples, as in FIG. 3, the brush head 202 is joined to the handle 204 by the ferrule 206. In some examples, the brush head 202 is joined directly to the handle 204. The brush head 202 has a height h and a width w. In some instances, the height h is measured from the ferrule 206 to a top of the brush head 202. In some instances, the height h is measured from the handle 204 to a top of the brush head 202. The width w is measured across a greatest width of the brush head 202.

In operation, the brush 200 is inserted into the brush gauge 100. In the example of FIG. 3, the brush 200 is inserted into the first aperture 196. The first aperture 196 is sized to accommodate and measure the brush 200. In some embodiments the second aperture 198 is sized differently from the first aperture 196 to measure brushes of a different size, as depicted in FIGS. 1, 2, 3, and 6. In some embodiments, the first aperture 196 and the second aperture 198 are sized substantially alike to accommodate and measure multiple same-sized brushes (not shown). More specifically, in operation, the brush 200 is inserted into the first aperture to abut the ferrule 206 against the first stepped barb 108 and the second stepped barb 110. Thus, in operation, the brush head 202 rests against the first top arcuate wall 146, the first top sloped wall 148, and the second top sloped wall 160. It should be appreciated that the brush 200 thus also rests against the first arcuate ledge 104, the first bottom arcuate wall 164, the first bottom sloped wall 166, and the second bottom sloped wall 168, which are obscured by the brush 200 in FIG. 3.

With reference to FIG. 7, an example testing system 300 includes the brush gauge 100, a controller 310, a sensor 320, and a light 330. The controller 310 is in communication with the sensor 320 and the light 330. The controller 310 includes a memory 350 and a processor 360. The controller may also be in communication with a quality management system. It should be understood that one or more sets of lights 330 and sensors 320 may be in communication with the controller 310.

Still referring to FIG. 7, the sensor 320 is a photoelectric sensor. In some embodiments, the sensor 320 may be a retro-reflective type sensor. In some embodiments, the sensor 320 may be a diffused type sensor. In some embodiments, the light 330 and the sensor 320 may form a through beam type sensor.

With reference again to FIG. 7, the light 330 may be a light emitting diode (LED), an incandescent bulb, a laser, an infrared emitter, etc.

Referring still to FIG. 7, the memory 350 is computer readable media on which one or more sets of instructions, such as the software for operating the methods of the present disclosure can be embedded. The instructions may embody one or more of the methods or logic as described herein. In a particular embodiment, the instructions may reside completely, or at least partially, within any one or more of the memory 350, the computer readable medium, and/or within the processor 360 during execution of the instructions.

The processor 360 may be any suitable processing device or set of processing devices such as, but not limited to: a microprocessor, a microcontroller-based platform, a suitable integrated circuit, one or more field programmable gate arrays (FPGAs), and/or one or more application-specific integrated circuits (ASICs). The memory 350 may be volatile memory (e.g., RAM, which can include non-volatile RAM, magnetic RAM, ferroelectric RAM, and any other suitable forms); non-volatile memory (e.g., disk memory, FLASH memory, EPROMs, EEPROMs, non-volatile solid-state memory, etc.), unalterable memory (e.g., EPROMs), read-only memory, and/or high-capacity storage devices (e.g., hard drives, solid state drives, etc.). In some examples, the memory 350 includes multiple kinds of memory, particularly volatile memory and non-volatile memory.

The terms “non-transitory computer-readable medium” and “tangible computer-readable medium” should be understood to include a single medium or multiple media, such as a centralized or distributed database, and/or associated caches and servers that store one or more sets of instructions. The terms “non-transitory computer-readable medium” and “tangible computer-readable medium” also include any tangible medium that is capable of storing, encoding or carrying a set of instructions for execution by a processor or that cause a system to perform any one or more of the methods or operations disclosed herein. As used herein, the term “tangible computer readable medium” is expressly defined to include any type of computer readable storage device and/or storage disk and to exclude propagating signals.

With reference to FIG. 7, in operation, the brush 200 is placed in the brush gauge 100. Further in operation, the brush 200 and the brush gauge 100 are placed between the light 330 and the sensor 320. The controller 310 illuminates the light 330. The sensor 320 detects whether any light beams 332 have passed through the brush gauge 100 past the brush 200. In other words, the sensor 320 detects whether there are any gaps between the brush 200 and the brush gauge 100.

FIG. 8 is a flowchart of a first example method 800 to verify brush head size, which may be implemented by the example electronic components of FIG. 7. The flowchart of FIG. 8 is representative of machine readable instructions stored in memory (such as the memory 350 of FIG. 7) that comprise one or more programs that, when executed by a processor (such as the processor 360 of FIG. 7), cause the testing system 300 to verify brush head (such as the brush head 202 of FIG. 3) dimensions. Further, although the example program(s) is/are described with reference to the flowchart illustrated in FIG. 8, many other methods of verifying brush head size may alternatively be used. For example, the order of execution of the blocks may be changed, and/or some of the blocks described may be changed, eliminated, or combined. Additionally, in some instances, an operator may perform one or more of the blocks described.

With reference to FIG. 8, initially, at block 802, the operator places one or more brushes (e.g., the example brush 200) in the brush gauge 100.

At block 804, the operator visually determines whether the brush head (e.g., the brush head 202) fits in the top portion 120.

If, at block 804, the operator determines that the brush head fits in the top portion 120, the method 800 proceeds to block 806.

If, at block 804, the operator determines that the brush head does not fit in the top portion 120, the method 800 proceeds to block 808.

At block 806, the operator visually determines whether the brush head (e.g., the brush head 202) passes through the brush gauge 100 via the bottom portion 122.

If, at block 806, the operator determines that the brush head passes through the brush gauge 100 via the bottom portion 122, the method 800 proceeds to block 808.

If, at block 806, the operator determines that the brush head does not pass through the brush gauge 100 via the bottom portion 122, the method 800 proceeds to block 810.

At block 810, the controller 310 illuminates the light 330 to shine on the brush gauge 100 and the brush 200. In some instances, the operator performs block 810 to illuminate the light 310.

At block 812 the controller 310 determines whether one or more light beams 332 have passed through the brush gauge 100 to be detected by the sensor 320. In some instances, the operator performs block 812 to visually determine whether one or more light beams 332 have passed through the brush gauge 100 (e.g., using a mirror).

If, at block 812, the controller 310 determines that one or more light beams 332 have passed through the brush gauge 100 to be detected by the sensor 320, the method 800 proceeds to block 808. In instances at block 812 where the operator visually determines that one or more light beams 332 have passed through the brush gauge 100, the method 800 proceeds to block 808.

If, at block 812, the controller 310 determines that one or more light beams 332 have not passed through the brush gauge 100 to be detected by the sensor 320, the method 800 proceeds to block 814. In instances at block 812 where the operator visually determines that one or more light beams 332 have not passed through the brush gauge 100 to be detected by the sensor 320, the method 800 proceeds to block 814.

At block 808, the controller 310 rejects the brush, logs the rejection, and displays the rejection to the operator. In some instances at block 808, the operator rejects the brush and logs the rejection. The method continues on to block 816.

At block 816, the operator discards the brush. The method then returns to block 802.

Returning to block 814, the controller 310 accepts the brush as OK, logs the acceptance, and displays the acceptance to the operator. In some instances, the operator accepts the brush as OK and logs the acceptance. The method continues on to block 818.

At block 818, the operator sends the brush for packaging (e.g., via a conveyor). The method then returns to block 802.

From the foregoing, it will be appreciated that the above example brush gauge 100 and testing system 300 aid in determining whether brush heads are correctly sized. Thus, fewer brushes with improperly-sized brush heads may reach consumers. Further, because the brushes with improperly-sized brush heads are kept at the brush manufacturing facility, the handles and/or ferrules of the brushes with improperly-sized brush heads may be salvaged for re-use. Thus, the above-disclosed brush gauge 100 and testing system 300 may aid in conserving materials and resources.

While various spatial and directional terms, such as top, bottom, lower, mid, lateral, horizontal, vertical, front, and the like may be used to describe examples of the present disclosure, it is understood that such terms are merely used with respect to the orientations shown in the drawings. The orientations may be inverted, rotated, or otherwise changed, such that an upper portion is a lower portion, and vice versa, horizontal becomes vertical, and the like.

Variations and modifications of the foregoing are within the scope of the present disclosure. It is understood that the examples disclosed and defined herein extend to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present disclosure. The examples described herein explain the best modes known for practicing the disclosure and will enable others skilled in the art to utilize the disclosure. The claims are to be construed to include alternative examples to the extent permitted by the prior art. 

What is claimed is:
 1. A brush gauge, comprising: a stepped barb; and an arcuate ledge, wherein the stepped barb and the arcuate ledge partially define an aperture.
 2. The brush gauge of claim 1, wherein the stepped barb is connected to the arcuate ledge by a sloped wall.
 3. The brush gauge of claim 1, wherein the arcuate ledge is a shoulder defined between a top arcuate wall and a bottom arcuate wall.
 4. The brush gauge of claim 1, wherein the stepped barb comprises a stepped wall, a top sloped wall, and a bottom sloped wall.
 5. The brush gauge of claim 1, wherein the stepped barb and the arcuate ledge extend into the aperture.
 6. The brush gauge of claim 1, further comprising an end wall partially defining the aperture opposite the arcuate ledge.
 7. The brush gauge of claim 1, wherein the aperture is formed of a top opening in communication with a bottom opening, the top opening being larger than the bottom opening.
 8. A brush gauge, comprising: an arcuate ledge; a first stepped barb connected to the arcuate ledge; and a second stepped barb connected to the arcuate ledge.
 9. The brush gauge of claim 8, wherein the first stepped barb is opposite the second stepped barb.
 10. The brush gauge of claim 8, wherein: the first stepped barb is connected to the arcuate ledge by a first sloped wall, and the second stepped barb is connected to the arcuate ledge by a second sloped wall.
 11. The brush gauge of claim 8, wherein the arcuate ledge is a shoulder defined between a top arcuate wall and a bottom arcuate wall.
 12. The brush gauge of claim 8, wherein the arcuate ledge, the first stepped barb, and the second stepped barb partially define an aperture.
 13. The brush gauge of claim 8, wherein: the first stepped barb comprises a first stepped wall, a first top sloped wall, and a first bottom sloped wall, and the second stepped barb comprises a second stepped wall, a second top sloped wall, and a second bottom sloped wall.
 14. The brush gauge of claim 8, further comprising an end wall connected to the first stepped barb and the second stepped barb and opposite the arcuate ledge.
 15. A brush gauge, comprising: a body defining an aperture and comprising a stepped barb extending into the aperture, and an arcuate ledge extending into the aperture.
 16. The brush gauge of claim 15, wherein the stepped barb is connected to the arcuate ledge by a sloped wall.
 17. The brush gauge of claim 15, wherein the arcuate ledge is a shoulder defined between a top arcuate wall and a bottom arcuate wall.
 18. The brush gauge of claim 15, wherein the stepped barb comprises a stepped wall, a top sloped wall, and a bottom sloped wall.
 19. The brush gauge of claim 15, wherein the stepped barb is a first stepped barb and further comprising a second stepped barb extending into the aperture.
 20. The brush gauge of claim 19, wherein the first stepped barb is opposite the second stepped barb. 